Service Procedure

1. Feed a # 10 or # 12 gauge wire parallel to the existing crankshaft position sensor wiring. The wire should extend above the serpentine belt tensioner and below the existing crankshaft position sensor in the front cover.

2. Raise the vehicle.

3. Remove the steering linkage shield (4 Wheel Drive only).

4. Verify the crankshaft position sensor P/N. The P/N is located on the bracket holding the sensor in place. If the stamped P/N ends in 254, replacement is necessary.

NOTICE:
All vehicles may not require a crankshaft sensor replacement.

5. If the crankshaft position sensor does not need to be replaced, no further action is required. Replace the steering linkage shield, torquing the bolts to 32 N-m. (4 Wheel Drive only)

Lower the vehicle. Remove the wire (installed in step # 1). The inspection is complete. Proceed to steps 28 and 29.

6. If crankshaft position sensor replacement is necessary: Continue with procedure.

7. On the engine front cover, open the lower plastic retaining clip and remove the lower section of crankshaft position sensor harness.

8. Remove the crankshaft position sensor retaining bolt and sensor from the engine front cover.

9. Cut the crankshaft position sensor wires at the crankshaft sensor.

10. On the replacement crankshaft position sensor (P/N 10456256):

- Carefully remove the locking collar on the connector.

- Using a suitable pin removal tool depress the locking tab inside each pin.

- Carefully remove the three (3) wires/pins from the connector and tape the pins together.

- Remove the existing plastic harness clips (2) from the harness.

11. Tape the wire/pins from the new sensor to the # 10 or # 12 gauge wire (installed in step # 1).

12. Lower the vehicle from the hoist. Remove the old crankshaft position sensor wiring harness by pulling up from the engine compartment. Removing the harness will pull a plastic "rosebud" fastener from the front cover bracket.

13. Carefully pull up on the # 10 or # 12 gauge feed wire (with new wire harness/sensor attached) to position the new harness between the front cover and water pump.

14. Carefully remove the wire harness from the feed wire. Remove the tape from the connector pins. Push out the locking tab on each connector pin, and re-install each pin in the connector with the following orientation:

Crankshaft Position Sensor Asm. Connector
Connector position "A" - White Wire
Connector position "B" - Black Wire
Connector position "C" - Red Wire

Engine Harness Connector
Connector position "A" - yellow wire
Connector position "B" - purple wire
Connector position "C" - pink wire

NOTICE:
PINS MUST BE FULLY INSERTED IN THE CONNECTOR AND LOCKED IN PLACE TO INSURE PROPER OPERATION.

Re-install the locking collar on the connector.

NOTICE:
FAILURE TO INSTALL THE WIRES IN THE CORRECT POSITION WILL RESULT IN A NO START CONDITION, OR SENSOR FAILURE AFTER ENGINE IS STARTED.

15. The sensor harness MUST be routed under the rear A/C compressor bracket. Connect the sensor harness to the engine wiring harness.

16. Raise the vehicle.

17. Check the threaded brass insert in the front cover which holds the crank position sensor/bracket. Run a straight edge across the face of the insert boss. The brass insert should NOT protrude above the front cover boss.

Also check for a loose brass insert. Insert the crankshaft sensor retaining bolt through a washer and fasten to the front cover. Torque the bolt to 7 N-m. If unable to obtain 7 N-m torque, the brass insert is loose and will need to be replaced. Remove the crankshaft sensor retaining bolt. (Go to step 18b).

18a. IF NO BRASS INSERT PROTRUSION OR LOOSENESS IS DETECTED, insert the new sensor into front cover.

NOTICE:
The sensor MUST BE FULLY SEATED in the front cover hole before installing the retaining bolt. If the sensor is not fully seated, the insert may be pulled out during the torquing procedure. This will result in an increased air gap between the sensor and crankshaft reluctor wheel. An incorrect air gap may result in ignition misfire and/or the illumination of the "Service Engine Soon" light.

Install the crankshaft sensor retaining bolt and torque to 7-9 N-m USING HAND TOOLS ONLY. DO NOT EXCEED THE TORQUE SPECIFICATION.

Re-install the steering linkage shield, if applicable, torquing the bolts to 32 N-m. Lower the vehicle, start and run the engine one (1) minute to verify proper crankshaft position sensor operation.

The repair is now complete. Proceed to steps 28. and 29.

18b. IF THE BRASS INSERT IS LOOSE OR PROTRUDING, the brass insert must be replaced.

Using the crankshaft sensor retaining bolt and a thick stack of washers (approx. 1/2 inch total height) with an I.D. larger than the O.D. of the insert, install the washer(s) between the bolt and insert. The washers must be CENTERED over the insert.

Slowly torque down the crankshaft sensor retaining bolt until the brass insert is pulled out of the front cover, through the center of the washer(s).

19. Clean the insert hole and surface area around it with shop air and a clean cloth.

20. Spray the inside of the insert hole with primer (P/N 12525680).

IMPORTANT:
Let the primer dry for five (5) minutes.

21. Using a saturated cotton swab, apply a generous layer of adhesive (P/N 12525679) to the outside of the new brass insert (P/N 10213295).

22. Using a small hammer, carefully tap the new brass insert into the front cover hole making sure the slotted end is inserted in the hole first. The brass insert must be flush, or slightly lower than the front cover surface.

23. Install the crankshaft position sensor. Check to see that the sensor is fully seated in the front cover hole prior to torquing down the retaining bolt. If the sensor is not fully seated, the insert may be pulled out during the torquing procedure. This will result in an increased air gap between the sensor and crankshaft reluctor wheel. An incorrect air gap may result in ignition misfire and/or the illumination of the "Service Engine Soon" light.

24. Torque the crankshaft sensor retaining bolt to 7-9 N-M. USING HAND TOOLS ONLY. DO NOT EXCEED THE TORQUE SPECIFICATION.

25. Install the new harness in the lower front cover clip. Check for sufficient clearance between the wiring harness and the harmonic balancer.

26. Aim and hold a heat gun at the newly installed crankshaft sensor retaining bolt head for five (5) minutes to cure the adhesive. Temperature should be approximately 250 degrees F.

NOTICE:
THIS STEP IS MANDATORY TO INSURE PROPER CURING OF RETAINING COMPOUND.

27. Re-install steering linkage shield, if applicable, torquing the bolts to 32 N-m.

28. Lower the vehicle, start and run the engine one (1) minute to verify crankshaft position sensor operation.

29. Install Campaign Identification Label.

30. Wash vehicle and fill fuel tank before returning unit to owner.